New developments. Technologies

Technologies for the production of basalt fibres using liquefied petroleum gas (LPG)

Our company offers the use of liquefied petroleum gas (LPG) for melting of basalt and basalt fiber production. Experts of our company have made the design of the furnaces consuming of LPG; and equipment for the production of basalt continuous fibres was launched with using of liquefied gas.

Application of LPG as a substitute for natural gas has a several features:

• LPG has high caloricity; it is equal to 24,000 - 27,000 kcal/m3. 
• Presence a large amount of carbon in the chemical composition.
• Instability of characteristics and parameters of LPG; LPG has not requirements to chemical composition and not regulated by State Standards

Usage of LPG for the melting of basaltic raw material and production the melts of the required parameters and characteristics were demanded of special developments.

BCF -1 plant using of liquefied petroleum gas started up successfully in Shanghai city, PR China.

We propose process plants for the production of basalt continuous fiber, super thin and staple fibres with usage of LPG as energy resources for Customers that have not natural gas for organization of fiber production.

Technologies making possible to use of associated petroleum gas for the production of basalt continuous fibres.

The use of associated petroleum gas (which is released during oil production) is an important task especially for oil producing countries, where torches of the associated gas just are burning on oil fields, polluting the environment.
Associated petroleum gas is a by-product of the production; it has a low cost.
The melting furnaces of special design were developed, where associated petroleum gas can be used for the melting of basalts and for the production of basalt continuous fiber (BCF), super thin (STBF), staple fibres (TBF) and heat insulating materials made from STBF and TBF.

Caloricity of an associated petroleum gas is lower than natural gas. This required the use of special gas burners and gas appliances to create the necessary temperature melting of basalts.
Our company offers process lines for the production of BCF, super thin and thin staple fibres, manufacturing equipment for the production of insulation slabs and cardboard for Customers who have an associated petroleum gas.
Our company has experience in the application of associated gas for the BCF production in the factory in Osa city, Perm krai.

Technologies of the basalt melting and homogenization of the melts at the production of basalt continuous fiber.

Specialists of our company completed a series of scientific and technological works for the development of technologies of the basalt melting and homogenizing of the melts at the production of basalt continuous fibre (BCF).

Technologies have reduced of gas consumption in the BCF production.

Consumption of natural gas and LPG for producing of 1 kg of BCF was decreased to 0.6 cubic meters.

These technologies were implemented in the new generations BCF 2 GM plants.  

Technologies and equipment for fusion of basalt and homogenizing basalt melts are new and patented.
Practical usage of new technological and technical solutions give possibility  reduce the production cost of BCF production and also get basalt melts that are suitable for the  production of basalt fibres  of more higher temperature applications.

Examples of the technologies application.

1. At sufficiently high prices for natural gas (it is 230 - 350 US dollars per 1,000 cubic meters); at the BCF production the share of the cost of gas does not exceed 12% in the total production cost value of the BCF marketable products.  Thus, the gas costs are not determinative in the production cost value of BCF.
2. Basalt continuous fibres for higher temperature applications are received.

The results of the works of technologies development were presented at the 4-th All-Russian Scientific and Practical Conference.

"TECHNICS AND TECHNOLOGY of heat-insulating materials from mineral raw materials"
- S.P.Osnos. «Researching of melting process of basalt at the basalt continuous fiber production», pages 171 – 176.
- S.P.Osnos «Researching of workability characteristics of basalt melts at the basalt continuous fiber production», pages 176 - 183.
- О.А. Mikryukova.  «Economic aspects of the production and application of continuous basalt fiber», pages 189 – 194.

Reports of the 4 - th All-Russian Scientific Conference. Moscow, FGUP "TSNIIHM", 2006.

Production of composite basalt-plastic materials and products. Basalt-plastic rebar. Section materials. Pipes.

Our company offers three types of the process equipment (pultrusion lines) for production of basalt-plastic rebar and section materials.

Supply of the pultrusion lines is carried out for BCF factories. The standard pultrusion line for production of basalt-plastic rebar and section materials is shown on the photo. 

Bobbin carrier for basalt fiber roving and the section for installing the bobbin carriers for feeding basalt fiber roving to the pultrusion process line Pultrusion process line for the production of basalt-plastic section materials and rebar

Process line for manufacturing of basalt-plastic rebar.

Basalt-plastic rebar of two types and basalt-plastic rods.

Manufacturing and usage of basalt reinforcement (rebar) has a great future. Strength characteristics of basalt-plastic rebar (BPR) in 2 - 2.5 times higher than the strength of steel reinforcement; BPR is not subject to corrosion.  Development of the production of BCF and basalt-plastic rebar (BPR) is such that the sales cost of BPR by 10 - 20% below than the price of steel reinforcement A3. Basalt-plastic rebar, due to their advantages and lower cost, will gradually replace the traditional steel reinforcement. In the coming years volumes of BPRebar production will grow exponentially. The corresponding tests of such materials were performed and normative documents - specifications and standards for the use of BPR have been developed by design institutions in Ukraine, China, and Russia and some other countries. In USA Standard ASTM for Composite reinforcement was developed.  With consideration of these factors, basalt continuous fiber is perspective material, specifically for use in production of basalt-plastic composite materials. More information see in Article Appliance of basalt fiber based materials in building and anti-seismic constructing.

Specimens of basalt-plastic tubes, suspension rods, and oil pump jack rods made from Basalt continuous Fiber and Glass fiber Basalt-plastic cores of overhead conductors for high-voltage power transmission lines 

Inorganic binders of NS -1 series for the production of thermal insulating materials on the basis of basalt and mineral fibres.

Inorganic adhesives and binding substances NS-1 series are used at the production of heat-insulating fibrous materials, such as: slabs, cardboard, semicylinders, lightweight insulating materials.
NS-1 adhesives, binders have density 1.2 - 1.4 kg / dm 3, depending on the modification. They have different temperatures of application; it is 6000C for NS-1B type; 9000С - for NS-1A, and up to 12000С - for NS-1F. 

Binders and adhesives NS-1 series are a one-component system of inorganic elements with additives based on metal oxides, capable to harden in normal conditions without applying high temperatures

Specimens of slabs, cardboard and material for false ceilings

NS-1 series binding substance constitutes a suspension of blue, yellow-green, gray and greenish colours.  They are non toxic, non-explosive, environmentally friendly products.

The specimens created on the basis of basalt fibres and NS-1B binder are shown on photo.

The main use of binders NS-1 series is the production of heat-insulating plates and lightweight refractory materials

Offers

1. Deliveries of binders for the production of fibrous insulating materials.
2. Supply of process equipment for the production of binders.
3. Deliveries of production equipment and technology for the production of binders.

Basalt continuous fiber for higher-temperatures application.

The technologies and technological equipment for production of basalt continuous fibers for higher temperature applications were developed.

Those skilled in the basalt fiber is known that  the strength of BCF  is  substantially reduced, on 50 - 60%,  at long term exposure of temperatures up to 600°C.

Thus for some fields of BCF applications, it is important to obtain fibers possessing by higher characteristics on heat resistance. This BCF used for the production of high-temperature filters, materials for automobile mufflers, automotive engine gaskets, heat-resistant materials for filtering of melts. The problem of obtaining BCF on higher temperatures of application is an actual task; and it was solved by the application of special technologies of melting of basalt rocks of specific chemical composition.

The main results.

1. BCF on long-term use at temperatures to 860°C -890°C was manufactured
2. Production technology of BCF (for long-term use at temperature to 860 - 890°C) provides the industrial production of such fibers and materials based on them. This basalt fiber is used for manufacturing of filtering meshes of high-temperature filters and meshes for filtering molten iron in the casting production. Testing of said meshes indicate that prolonged exposure to a flame at a temperature up to 900°C is reducing their tensile strength insignificantly, by 10 - 15%.

The specimens of filter meshes made on the basis of BCF of higher temperature applications are shown in the photos.

Meshes, made from thermal-resistant BCF, are used for filtering of melt metal in the casting of engine casings cars.

Foamed heat insulating materials

The production technologies of foamed heat insulating materials were developed. Heat insulation porous materials in characteristics and appearance are similar to the materials made from foamed glass. The working title of the material is "Penoizol" (it was proposed by our partners - the STC "Korda" ).

Materials "Penoizol" are produced by "cold" technologies without the use of high temperatures. The inorganic components, such as: filler, binder, reinforcing fibers, foaming agent, are the feedstock for the production.  Foaming of liquid mass of the inorganic components takes place at temperatures of 20 - 25 °C. Then, the material is dried in drying chambers or drying plant. It is possible to produce of the foamed materials at the place of application.

Power inputs for the production of foamed thermal insulation materials are minimal compared with the production of foamed glass or heat-insulating materials based on basalt and mineral fibers.      

Material is non-flammable, temperature of long term application is up to + 600°C. It is possible to produce materials for temperature applications up to 900°C.   Material does not emit any substances when heated or exposed to an open flame. Pores of the material are closed. 

Specimen of 'Penoizol' material 

The density of material is 40 – 120 kg/m3

The thermal conductivity of the material is 0.045 W/m, if the density of the material is equal to 40 kg/m3; if density is 100 kg/m3 the thermal conductivity is 0.064 W/m (at the temperature of 25°С). When the density is more than 120 kg / m3, the material possess enough high strength, and can be used as a structural, thermal insulating material.

"Penoizol» material has good insulating properties, strength and water resistance.  Products from the "Penoizol", including: slabs, semicylinders for pipe insulation, and products of complex shape; the insulation of internal cavities that are not available can be made at the place of use.